EP0505708A1 - Coated metal fastener and coating composition therefor - Google Patents
Coated metal fastener and coating composition therefor Download PDFInfo
- Publication number
- EP0505708A1 EP0505708A1 EP92102230A EP92102230A EP0505708A1 EP 0505708 A1 EP0505708 A1 EP 0505708A1 EP 92102230 A EP92102230 A EP 92102230A EP 92102230 A EP92102230 A EP 92102230A EP 0505708 A1 EP0505708 A1 EP 0505708A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- metal fastener
- coating
- monomer
- fastener
- copolymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 42
- 239000002184 metal Substances 0.000 title claims abstract description 42
- 239000008199 coating composition Substances 0.000 title claims abstract description 38
- 229920001577 copolymer Polymers 0.000 claims abstract description 26
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000000203 mixture Substances 0.000 claims abstract description 17
- 239000003960 organic solvent Substances 0.000 claims abstract description 15
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 10
- 239000011505 plaster Substances 0.000 claims abstract description 10
- 239000003849 aromatic solvent Substances 0.000 claims abstract description 5
- 150000002576 ketones Chemical class 0.000 claims abstract description 5
- 238000000576 coating method Methods 0.000 claims description 61
- 239000011248 coating agent Substances 0.000 claims description 55
- 229920005989 resin Polymers 0.000 claims description 27
- 239000011347 resin Substances 0.000 claims description 27
- 239000000178 monomer Substances 0.000 claims description 26
- 125000003118 aryl group Chemical group 0.000 claims description 11
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 10
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 claims description 6
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- -1 chlorohydrocarbons Substances 0.000 claims description 4
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 238000007598 dipping method Methods 0.000 claims description 3
- 239000001530 fumaric acid Substances 0.000 claims description 3
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 claims description 3
- 239000011976 maleic acid Substances 0.000 claims description 3
- 229920003002 synthetic resin Polymers 0.000 claims description 3
- 239000000057 synthetic resin Substances 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims description 2
- 125000003011 styrenyl group Chemical group [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 claims 1
- 229920002689 polyvinyl acetate Polymers 0.000 abstract description 13
- 239000011118 polyvinyl acetate Substances 0.000 abstract description 13
- 238000007796 conventional method Methods 0.000 abstract 1
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 21
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 12
- 238000006243 chemical reaction Methods 0.000 description 12
- 239000011701 zinc Substances 0.000 description 12
- 229910052725 zinc Inorganic materials 0.000 description 12
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 10
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 10
- 150000001875 compounds Chemical class 0.000 description 8
- 239000002904 solvent Substances 0.000 description 8
- 239000000975 dye Substances 0.000 description 7
- UOCLXMDMGBRAIB-UHFFFAOYSA-N 1,1,1-trichloroethane Chemical compound CC(Cl)(Cl)Cl UOCLXMDMGBRAIB-UHFFFAOYSA-N 0.000 description 6
- 229910000975 Carbon steel Inorganic materials 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 5
- 239000010962 carbon steel Substances 0.000 description 5
- 229920006026 co-polymeric resin Polymers 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000002253 acid Substances 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- 125000001931 aliphatic group Chemical group 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 229920002554 vinyl polymer Polymers 0.000 description 3
- XRASPMIURGNCCH-UHFFFAOYSA-N zoledronic acid Chemical compound OP(=O)(O)C(P(O)(O)=O)(O)CN1C=CN=C1 XRASPMIURGNCCH-UHFFFAOYSA-N 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- 241000587161 Gomphocarpus Species 0.000 description 2
- 150000008064 anhydrides Chemical class 0.000 description 2
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 2
- HRYZWHHZPQKTII-UHFFFAOYSA-N chloroethane Chemical compound CCCl HRYZWHHZPQKTII-UHFFFAOYSA-N 0.000 description 2
- 229960003750 ethyl chloride Drugs 0.000 description 2
- WOLATMHLPFJRGC-UHFFFAOYSA-N furan-2,5-dione;styrene Chemical compound O=C1OC(=O)C=C1.C=CC1=CC=CC=C1 WOLATMHLPFJRGC-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000007761 roller coating Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- KPAPHODVWOVUJL-UHFFFAOYSA-N 1-benzofuran;1h-indene Chemical compound C1=CC=C2CC=CC2=C1.C1=CC=C2OC=CC2=C1 KPAPHODVWOVUJL-UHFFFAOYSA-N 0.000 description 1
- FFRBMBIXVSCUFS-UHFFFAOYSA-N 2,4-dinitro-1-naphthol Chemical compound C1=CC=C2C(O)=C([N+]([O-])=O)C=C([N+]([O-])=O)C2=C1 FFRBMBIXVSCUFS-UHFFFAOYSA-N 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000906 Bronze Inorganic materials 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 240000007817 Olea europaea Species 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 229920002367 Polyisobutene Polymers 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 125000004063 butyryl group Chemical group O=C([*])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000004532 chromating Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 230000032050 esterification Effects 0.000 description 1
- 238000005886 esterification reaction Methods 0.000 description 1
- 150000002148 esters Chemical group 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000005002 finish coating Substances 0.000 description 1
- 239000011084 greaseproof paper Substances 0.000 description 1
- 239000000976 ink Substances 0.000 description 1
- 229910000398 iron phosphate Inorganic materials 0.000 description 1
- WBJZTOZJJYAKHQ-UHFFFAOYSA-K iron(3+) phosphate Chemical compound [Fe+3].[O-]P([O-])([O-])=O WBJZTOZJJYAKHQ-UHFFFAOYSA-K 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000003791 organic solvent mixture Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 150000004671 saturated fatty acids Chemical class 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B15/00—Nails; Staples
- F16B15/0092—Coated nails or staples
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D135/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least another carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Coating compositions based on derivatives of such polymers
- C09D135/06—Copolymers with vinyl aromatic monomers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2258/00—Small objects (e.g. screws)
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2401/00—Form of the coating product, e.g. solution, water dispersion, powders or the like
- B05D2401/10—Organic solvent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L31/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid; Compositions of derivatives of such polymers
- C08L31/02—Homopolymers or copolymers of esters of monocarboxylic acids
- C08L31/04—Homopolymers or copolymers of vinyl acetate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S411/00—Expanded, threaded, driven, headed, tool-deformed, or locked-threaded fastener
- Y10S411/90—Fastener or fastener element composed of plural different materials
- Y10S411/901—Core and exterior of different materials
- Y10S411/902—Metal core
- Y10S411/903—Resinous exterior
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S411/00—Expanded, threaded, driven, headed, tool-deformed, or locked-threaded fastener
- Y10S411/922—Nail, spike or tack having locking device
Definitions
- the invention herein relates to a coating for metal fasteners.
- the coating protects the metal fastener and exhibits an attraction for plaster-like materials.
- Fasteners such as nails, staples, and truss plates are utilized extensively in the construction and assembly of countless articles from buildings to fences.
- the useful life of a fastener is critical to its suitability for a particular purpose. For example, a nail which is not corrosion-resistant is not suited for service where it will be exposed to outdoor weather conditions.
- a suitable fastener coating must adequately adhere to the fastener.
- fasteners are made of carbon steel.
- Fasteners can also be made of aluminum or copper alloys such as bronze.
- a fastener may be zinc coated or chromate coated before a protective outer coating is applied. A suitable coating should therefore adhere to a variety of metals or metallic surfaces.
- Coatings for fasteners impart desirable properties to the fasteners. For example, most protective coatings on metal fasteners provide corrosion resistance, but some coatings enable a fastener to be inserted with less force yet increase the force required to remove the fastener.
- a fastener coating with both above-described properties is disclosed in Lat et al., U.S. Patent No. 4,964,774.
- the coating disclosed in the Lat et al. patent comprises a film forming, thermoplastic, predominantly aliphatic polyurethane resin, which is applied onto the fastener in an aqueous medium and then dried thereon.
- a metal coating composition comprising a copolymer of a vinyl halide, a vinyl ester of a lower saturated fatty acid and an aliphatic ⁇ , ⁇ -mono-olefinic carboxylic acid that exhibits improved adhesion to smooth metal surfaces is disclosed.
- the adhesion of the coating composition is improved by co-polymerizing the vinyl halide and the aliphatic vinyl ester with small quantities of an unsaturated carboxylic acid.
- a metal fastener coating that adheres to wood is disclosed.
- the coating comprises about 50 to about 80 percent by weight resin solids of a rosin-like resin, which is dispersed in about 20 to 50 percent by weight of an ethylene copolymer or terpolymer containing carboxyl or esterified carboxyl groups.
- porous materials such as plaster due to the chemical and physical properties of porous materials.
- the binder polymer in the plaster must be compatible, chemically, to the fastener overcoat for good adhesion to develop on drying.
- plaster-like materials such as spackling compound are applied as a finish over sheets of plasterboard which have been fastened to building frames. If the fastener used does not exhibit some sort of affinity for the spackling compound, the spackling compound will not adhere to those portions of the fastener not embedded in the plasterboard. If the spackling compound does not adhere to the exposed portions of the fastener, the finish coating will be uneven or pocked, which is unacceptable.
- the present invention is directed to a coated metal fastener and a coating therefor.
- the coating composition reduces penetration force, increases withdrawal force, and resists chipping or tearing away the article or object into which the fastener is imbedded or otherwise anchored.
- the coating further protects the metal fastener from corrosion.
- the coating has a strong attraction to plaster and plaster-like materials, which more readily adhere to the coated fastener herein disclosed.
- the coating is a combination of two resins.
- the first resin is a copolymer of an aromatic monomer, preferably styrene, and a monomer with ⁇ , ⁇ unsaturation associated with carboxyl groups or partially esterified carboxyl groups, preferably maleic anhydride.
- the second resin is a thermoplastic resin, preferably vinyl acetate.
- the coating composition is prepared by combining about 4% to about 15%, preferably about 7.5 weight percent of the copolymer resin with about 3% to about 16%, preferably about 5 weight percent of the thermoplastic resin in an inert organic solvent or mixture of solvents.
- the ratio of the first resin to the second resin is about 80 to 20 to about 20 to 80 parts by weight.
- the inert organic solvents can be aromatic solvents, ketones, chlorohydrocarbons, and mixtures thereof. Preferred solvents are toluene, methylethylketone, and chloroethane, 1,1,1 trichloroethane being the most preferred.
- the organic solvent generally comprises about 80 to 90 percent by weight of the coating composition, preferably about 87 percent by weight.
- the coating composition optionally contains a dye which, if present, is in an amount of about 0.1% to about 1%, preferably about 0.2 percent by weight of the composition.
- the coating composition is suited for application onto metal fasteners made preferably of carbon steel.
- the fastener itself may be a nail, staple, or truss plate.
- thermoplastic, polymeric coating is applied to the fastener by dipping, spraying or roller coating the fastener with the coating composition in inert organic solvent.
- a reservoir filled with the coating composition is provided for this purpose.
- the liquid coating composition is then cured and dried on the fastener by conventional means.
- the coating is dried upon the fastener at approximately ambient temperature.
- the thickness of the dried coating composition on the fastener is about 0.2 to about 2 millimeters, preferably about 0.5 to about 1.5 millimeters.
- the cured coating composition is sufficiently brittle that, if bridges of dried coating should form between individual fasteners, these bridges can be broken without damaging the coating on either fastener.
- thermoplastic, polymeric coating is applied by any of the above-described methods so as to coat a substantial part of the fastener, preferably the entire fastener.
- FIGURE 1 is an elevational view of a nail constituting a preferred embodiment of this invention.
- FIGURE 2 is a cross-sectional view on a slightly larger scale, as taken along plane 2--2 of FIGURE 1 in a direction indicated by arrows.
- FIGURE 3 is a simplified perspective view of a collated coil of nails.
- FIGURE 4 is an elevational view on a slightly smaller scale, showing a fragmentary, collated strip of nails from the coil of FIGURE 3 similar to the nail of FIGURE 1.
- FIGURE 5 is a perspective view of a staple constituting an alternative embodiment of this invention.
- FIGURE 6 is a simplified, perspective view of a truss plate constituting a further embodiment of this invention.
- the present invention is directed to a coating composition for a metal fastener, a metal fastener coated with the coating composition and a method for coating the metal fastener with the coating composition.
- the coating composition is a combination of a copolymer and a thermoplastic resin.
- the copolymer contains an aromatic monomer and a monomer with ⁇ , ⁇ unsaturation associated with carboxyl groups or partially esterified carboxyl groups.
- the copolymer and resin are combined in an inert organic solvent and applied to the metal fastener by any suitable method, preferably dipcoating.
- Aromatic monomers suitable for use in the invention are styrene, vinyl toluene ⁇ -methylstyrene, ⁇ -methylstyrene, divinylbenzene and the like. Styrene is preferred due to its greater availability and lower cost. Polymers made from aromatic monomers tend to be stiff and clear. Therefore, the aromatic monomer provides a degree of rigidity to the cured coating.
- Aromatic monomers are commonly copolymerized with other monomers. Monomers with ⁇ , ⁇ unsaturation with carboxyl or partially esterified carboxyl groups copolymerize with aromatic monomers to form linear, strong polymers. After copolymerization, a portion of the anhydride in the resulting polymer can be partially esterified, in which case a linear aromatic polyester resin is formed.
- Exemplary of monomers with ⁇ , ⁇ unsaturation with carboxyl groups are maleic anhydride, maleic acid and fumaric acid.
- the preferred monomer is maleic anhydride.
- Styrene/maleic anhydride copolymers preferred for use in the coating composition disclosed herein are preferably unmodified copolymers of styrene and maleic anhydride monomers with mole ratios of styrene to maleic anhydride monomer of about 1 to 1 to about 3 to 1.
- the copolymer has a relatively high melting temperature, in the range of about 55°C to about 170°C and a high thermal stability.
- the number average molecular weight of the resin is about 1600 to about 2800.
- the copolymer has an acid number of about 100 to about 500. The acid number is the number of milligrams of potassium hydroxide necessary to neutralize the acid in one gram of substance.
- the copolymer has a melt viscosity of about 15 cps to about 55 cps in a mixture that is about 15 percent nonvolatile material.
- the copolymer is soluble in a number of organic solvents. The solution viscosity and the solubility of the copolymer in the solution both increase as the ratio of styrene monomer to maleic anhydride monomer increases.
- the copolymer can be either in the anhydride or partial ester form.
- the copolymer can be partially esterified by treating the styrene/maleic anhydride copolymer with an alcohol such as ethylene glycol.
- the preferred degree of esterification of the copolymer is about 35 percent to about 50 percent.
- Thermoplastic synthetic resin adhesives comprise a variety of polymerized materials such as polyvinyl acetate, polyvinyl butyryl, polyvinyl alcohol, and other polyvinyl resins.
- Acrylic and methacrylic acid ester resins and various other synthetic resins such as polyisobutylene, polyamides, coumarone-indene products and silicones also exhibit adhesive properties desirable for the coating composition disclosed herein.
- the thermoplastic resins usually have permanent solubility and fusibility so that they creep under stress and soften when heated.
- the preferred thermoplastic resin herein is polyvinyl acetate (PVAc) which has demonstrated affinity for plaster and plaster-like compositions.
- the PVAc resin used in the composition disclosed herein can be in the form of beads such as VINAC beads manufactured by Air Products and Chemicals Inc.
- VINAC is a registered trademark of Air Products and Chemicals, Inc.
- PVAc resins are typically small, glass-like beads which have a number of uses such as laminating, label and hot melt adhesives, pigmented and grease-proof paper coatings, over print varnishes, industrial lacquers and coatings, printing inks, and textile sizes and finishes.
- PVAc resin is resistant to attack by weak acids, alkalies and salts, but is soluble in many organic solvents.
- PVAc resin generally has a softening point above about 120°C to about 165°C.
- Suitable PVAc resins generally have a molar viscosity of about 10 cps to about 75 cps in organic solvent.
- the number average molecular weight of the PVAc resin is about 90,000 to about 500,000.
- the resin contains no more than about 2% by weight volatile components.
- the ratio of styrene/maleic anhydride copolymer to PVAc resin in the coating composition is about 20:80 to about 80:20 parts by weight.
- the copolymer and resin are combined in an inert organic solvent.
- Organic solvents suitable for this application can be an aromatic solvent, a ketone, a chlorohydrocarbon and mixtures thereof. Solvents that will evaporate quickly at room temperature are preferred. Preferred solvents are toluene, methylethylketone and chloroethane, most preferably 1,1,1 trichloroethane.
- the organic solvent generally constitutes about 70 to about 95 parts by weight of the coating composition, most preferably about 87 percent by weight.
- the coating is then applied to the fastener by dipping, spraying, roller coating or another standard technique, such as by any of the techniques disclosed in Lat et al., U.S. Patent No. 4,964,774, the teachings of which are incorporated herein by reference.
- the liquid coating composition preferably has a low viscosity so that drops of coating do not form on the fastener when it is removed from the coating bath.
- the coated metal fastener is then removed from the coating bath and is dried at about ambient temperature. This is below the softening temperature of the thermoplastic resin in the coating composition. Preferably the temperature is in the range of about 60°F (15°C) to 100°F (38°C).
- the polymer in the coating may or may not be cross-linked. The degree of cross-linking in a particular instance is dependent upon the specific composition of the resin dispersed in the solvent and the cross-linking agent, and/or accelerators that may be present.
- bridges of coating may form between individual fasteners. When dry, these bridges are brittle and break easily without damaging the coating on the fasteners to which the bridges are attached.
- a coating composition was prepared in which methylethylketone (MEK) solvent (150 lbs), 1,1,1 trichloroethane solvent (130 lbs) and toluene solvent (12 lbs) were combined.
- MEK methylethylketone
- a styrene/maleic anhydride copolymeric resin 35 lbs) (2625 A Resin obtained from Atochem, Inc.) and a polyvinyl acetate resin (25 lbs) (VINAC B-100 Resin obtained from Air Products Corp.) were uniformly dispersed in the organic solvent mixture using mechanical mixing.
- the coating composition contained 13 ⁇ 0.25 percent solids, which was determined by using an evaporation method.
- the coating composition had an estimated viscosity of about 16-18 seconds using a #2 Zahn Cup.
- a coated nail 10, as shown in FIGURES 1 and 2 constitutes a preferred embodiment of this invention.
- the head 11 of the coated nail 10 is cupped, in a known manner, so as to provide a reservoir for a spackling compound applied over the coated nail 10.
- the coated nail 10 has a metal body 12, which is made of carbon steel, preferably AISI C 1008 steel. Its metal surfaces are covered completely with an inner zinc layer 14, an intermediate chromate conversion layer 16, and an outer copolymer/thermoplastic resin coating 18.
- the inner zinc layer 14, as applied by a known electroplating process, has a thickness of at least 0.5 mm so as to comply with Federal Building Code FF-N-105B, which is referenced to ASTM Specification A641, Class 1, Type 2.
- the chromate conversion layer 16 is a golden yellow (yellow iridescent) chromate conversion layer.
- a dark olive drab or dark black chromate conversion layer may be alternatively applied over the zinc layer 14, if desired.
- the other copolymer/thermoplastic resin coating 18 has a thickness of about 0.2 mm to about 2 mm, preferably about 0.5 mm to 1.5 mm.
- a plurality of coated nails 20, each of which is similar to the coated nail 10, are collated into a coil, to be coated generally as disclosed in Langas et al. U.S. Pat. No. 3,276,576.
- Each nail 20 has a cupped head 19 similar to the cupped head 11 of the coated nail 10.
- each coated nail 20 is situated in a rubber band 21 and formed into a coil 20.
- the metal surfaces of each coated nail 20 are covered completely with an inner zinc layer 14, as described above, and with an intermediate chromium conversion layer 16, as described above.
- FIGURE 4 is a detailed view of a few coated nails in a coil which fits a magazine (not shown) of a fastener driving tool.
- the wires 22 are affixed to the coated nails 20 by welds 23.
- the zinc and chromate conversion layers are applied to each coated nail 20 before such coated nail 20 is situated between and welded to the wires 22.
- a coated staple 30, as shown in FIGURE 5, constitutes yet another embodiment of this invention.
- the coated staple 30 has a metal body, which is made of carbon steel, preferably AISI C 1008 steel. Its metal surfaces are covered completely with an inner zinc layer, as described above, an intermediate chromate conversion layer, as described above, and an outer, copolymer/thermoplastic resin coating, as described above.
- the coated staple 30 may be one of a series (not shown) of similar staples that are collated.
- the outer coating on each of such staples, including the coated staple 30, may be advantageously used to collate the staples by applying the coating to the staples after the staples have been placed in a series, in side-to-side relation to one another.
- a coated truss plate 40, as shown in FIGURE 6 constitutes yet another embodiment of this invention.
- the coated truss plate 40 is formed from a planar member 42, from which a plurality of pointed teeth 44 are struck.
- the truss plate 40 usually is made of carbon steel, such as AISI C 1008 steel.
- the truss plate 40 is covered in its entirety with an inner zinc layer, as described above, an intermediate chromium conversion layer, as described above, and an outer coating, as described above.
- the coated truss plate 40 may be alternatively made from a galvanized, i.e., zinc-coated, steel sheet, which sheet has been galvanized in a hot-dip or other process.
- a galvanized i.e., zinc-coated, steel sheet
- the teeth 44 are struck from the planar member 42, the edges of the teeth 44 and the edges of the openings left in the planar member 42 by the teeth 44 are exposed without any zinc coating on the exposed edges.
- the truss plate 40 may be then immersed in a phosphating bath so as to apply a phosphate coating on the exposed edges as well as on the other parts of the metal body.
- a zinc phosphate coating is preferred.
- An iron phosphate coating may be alternatively applied.
- an intermediate chromate conversion layer, as described above, and an outer, coating, as described above, are applied to the truss plate 40 in its entirety.
- the intermediate chromium conversion layer may be optionally omitted.
- Nails made of AISI C 1008 steel are first cleaned in an alkaline earth metal bath, rinsed, pickled in an acidic bath, rinsed, galvanized, and rinsed again.
- the nails are galvanized so as to comply with ASTM Specification A641, Class 1, Type 2.
- a chromate conversion layer is applied to the nails. Thereafter, the thus treated nails are rinsed and over-coated.
- Nails which have been galvanized and chromated are preferred to be coated with the coating composition. It is envisioned that the composition can be applied to fasteners that have not been galvanized or chromated but upon which the properties imparted by the coating would be desirable.
- the nails are collated into coils by means of the wires 22.
- the coils are dipped into bath of coating composition as described in Example 1 above, to provide a dry coat thickness of about 0.5 mm to about 1.5 mm.
- the coating composition has a viscosity of less than about 100 cps.
- the coating is dried in a circulating air atmosphere at about ambient temperature, preferably about 60°F (15°C) to 100°F (38°C).
- bridges of coating between the nails may form even though the coating composition has a low viscosity. These bridges of coating harden as the coating is dried. These bridges could be problematic if they were too rigid and therefor not easily broken. For example, a coated coil of nails that is placed in a magazine of a driving tool would be unsatisfactory if the coating bridges caused the nails to bind in the magazine. Also, if the bridges, when broken, removed portions of the coating on the fastener, the fastener would be less effective for its intended purpose.
- the copolymer/thermoplastic resin coating is brittle when dried, the bridges that form during the coating process can be easily broken without damaging the coating on the fastener itself.
- the desired brittleness is provided by the styrene monomer in the copolymer.
- the coated fastener has a demonstrated affinity for plaster and plaster-like materials.
- the nails are thus particularly suited for use in drywall or plasterboard applications to fasten the plasterboard to wooden frames.
- a plaster spackling compound is applied over the seams and the exposed nail heads to make a uniform surface. If the spackling compound does not adhere to the nail head it may be visible through the overcoat, or a pocked or otherwise uneven surface could result. The appearance of the resulting surface would be unacceptable. Because the coating composition of the present invention has a demonstrated affinity for plaster-like materials, the spackling compound or other plaster based overcoat adheres to the fastener head and the desired uniform overcoat appearance is obtained.
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Abstract
Description
- The invention herein relates to a coating for metal fasteners. The coating protects the metal fastener and exhibits an attraction for plaster-like materials.
- Fasteners such as nails, staples, and truss plates are utilized extensively in the construction and assembly of countless articles from buildings to fences. The useful life of a fastener is critical to its suitability for a particular purpose. For example, a nail which is not corrosion-resistant is not suited for service where it will be exposed to outdoor weather conditions.
- Coatings for fasteners have been developed to protect metal fasteners from adverse conditions. A suitable fastener coating must adequately adhere to the fastener. Typically, fasteners are made of carbon steel. Fasteners can also be made of aluminum or copper alloys such as bronze. A fastener may be zinc coated or chromate coated before a protective outer coating is applied. A suitable coating should therefore adhere to a variety of metals or metallic surfaces.
- Coatings for fasteners impart desirable properties to the fasteners. For example, most protective coatings on metal fasteners provide corrosion resistance, but some coatings enable a fastener to be inserted with less force yet increase the force required to remove the fastener. A fastener coating with both above-described properties is disclosed in Lat et al., U.S. Patent No. 4,964,774. The coating disclosed in the Lat et al. patent comprises a film forming, thermoplastic, predominantly aliphatic polyurethane resin, which is applied onto the fastener in an aqueous medium and then dried thereon.
- In Campbell, Jr., U.S. Patent No. 2,329,456, a metal coating composition comprising a copolymer of a vinyl halide, a vinyl ester of a lower saturated fatty acid and an aliphatic α, β-mono-olefinic carboxylic acid that exhibits improved adhesion to smooth metal surfaces is disclosed. The adhesion of the coating composition is improved by co-polymerizing the vinyl halide and the aliphatic vinyl ester with small quantities of an unsaturated carboxylic acid.
- In Parkison, U.S. Patent No. 3,853,606, a metal fastener coating that adheres to wood is disclosed. The coating comprises about 50 to about 80 percent by weight resin solids of a rosin-like resin, which is dispersed in about 20 to 50 percent by weight of an ethylene copolymer or terpolymer containing carboxyl or esterified carboxyl groups.
- Even if coated, metal fasteners frequently do not satisfactorily anchor in porous materials such as plaster due to the chemical and physical properties of porous materials. Generally, the binder polymer in the plaster must be compatible, chemically, to the fastener overcoat for good adhesion to develop on drying.
- Frequently, plaster-like materials such as spackling compound are applied as a finish over sheets of plasterboard which have been fastened to building frames. If the fastener used does not exhibit some sort of affinity for the spackling compound, the spackling compound will not adhere to those portions of the fastener not embedded in the plasterboard. If the spackling compound does not adhere to the exposed portions of the fastener, the finish coating will be uneven or pocked, which is unacceptable.
- Therefore, a metal fastener coating which exhibits some affinity or attraction to plaster or plaster-like materials would be highly desirable.
- The present invention is directed to a coated metal fastener and a coating therefor. The coating composition reduces penetration force, increases withdrawal force, and resists chipping or tearing away the article or object into which the fastener is imbedded or otherwise anchored. The coating further protects the metal fastener from corrosion. The coating has a strong attraction to plaster and plaster-like materials, which more readily adhere to the coated fastener herein disclosed.
- According to this invention, the coating is a combination of two resins. The first resin is a copolymer of an aromatic monomer, preferably styrene, and a monomer with α,β unsaturation associated with carboxyl groups or partially esterified carboxyl groups, preferably maleic anhydride. The second resin is a thermoplastic resin, preferably vinyl acetate.
- The coating composition is prepared by combining about 4% to about 15%, preferably about 7.5 weight percent of the copolymer resin with about 3% to about 16%, preferably about 5 weight percent of the thermoplastic resin in an inert organic solvent or mixture of solvents. The ratio of the first resin to the second resin is about 80 to 20 to about 20 to 80 parts by weight.
- The inert organic solvents can be aromatic solvents, ketones, chlorohydrocarbons, and mixtures thereof. Preferred solvents are toluene, methylethylketone, and chloroethane, 1,1,1 trichloroethane being the most preferred. The organic solvent generally comprises about 80 to 90 percent by weight of the coating composition, preferably about 87 percent by weight.
- The coating composition optionally contains a dye which, if present, is in an amount of about 0.1% to about 1%, preferably about 0.2 percent by weight of the composition.
- The coating composition is suited for application onto metal fasteners made preferably of carbon steel. The fastener itself may be a nail, staple, or truss plate.
- The thermoplastic, polymeric coating is applied to the fastener by dipping, spraying or roller coating the fastener with the coating composition in inert organic solvent. A reservoir filled with the coating composition is provided for this purpose. The liquid coating composition is then cured and dried on the fastener by conventional means. The coating is dried upon the fastener at approximately ambient temperature. The thickness of the dried coating composition on the fastener is about 0.2 to about 2 millimeters, preferably about 0.5 to about 1.5 millimeters. The cured coating composition is sufficiently brittle that, if bridges of dried coating should form between individual fasteners, these bridges can be broken without damaging the coating on either fastener.
- The thermoplastic, polymeric coating is applied by any of the above-described methods so as to coat a substantial part of the fastener, preferably the entire fastener.
- FIGURE 1 is an elevational view of a nail constituting a preferred embodiment of this invention.
- FIGURE 2 is a cross-sectional view on a slightly larger scale, as taken along
plane 2--2 of FIGURE 1 in a direction indicated by arrows. - FIGURE 3 is a simplified perspective view of a collated coil of nails.
- FIGURE 4 is an elevational view on a slightly smaller scale, showing a fragmentary, collated strip of nails from the coil of FIGURE 3 similar to the nail of FIGURE 1.
- FIGURE 5 is a perspective view of a staple constituting an alternative embodiment of this invention.
- FIGURE 6 is a simplified, perspective view of a truss plate constituting a further embodiment of this invention.
- The present invention is directed to a coating composition for a metal fastener, a metal fastener coated with the coating composition and a method for coating the metal fastener with the coating composition. The coating composition is a combination of a copolymer and a thermoplastic resin. In particular the copolymer contains an aromatic monomer and a monomer with α,β unsaturation associated with carboxyl groups or partially esterified carboxyl groups. The copolymer and resin are combined in an inert organic solvent and applied to the metal fastener by any suitable method, preferably dipcoating.
- Aromatic monomers suitable for use in the invention are styrene, vinyl toluene ρ-methylstyrene, α-methylstyrene, divinylbenzene and the like. Styrene is preferred due to its greater availability and lower cost. Polymers made from aromatic monomers tend to be stiff and clear. Therefore, the aromatic monomer provides a degree of rigidity to the cured coating.
- Aromatic monomers are commonly copolymerized with other monomers. Monomers with α,β unsaturation with carboxyl or partially esterified carboxyl groups copolymerize with aromatic monomers to form linear, strong polymers. After copolymerization, a portion of the anhydride in the resulting polymer can be partially esterified, in which case a linear aromatic polyester resin is formed.
- Exemplary of monomers with α,β unsaturation with carboxyl groups are maleic anhydride, maleic acid and fumaric acid. The preferred monomer is maleic anhydride.
- Styrene/maleic anhydride copolymers preferred for use in the coating composition disclosed herein are preferably unmodified copolymers of styrene and maleic anhydride monomers with mole ratios of styrene to maleic anhydride monomer of about 1 to 1 to about 3 to 1. The copolymer has a relatively high melting temperature, in the range of about 55°C to about 170°C and a high thermal stability. The number average molecular weight of the resin is about 1600 to about 2800. The copolymer has an acid number of about 100 to about 500. The acid number is the number of milligrams of potassium hydroxide necessary to neutralize the acid in one gram of substance.
- The copolymer has a melt viscosity of about 15 cps to about 55 cps in a mixture that is about 15 percent nonvolatile material. The copolymer is soluble in a number of organic solvents. The solution viscosity and the solubility of the copolymer in the solution both increase as the ratio of styrene monomer to maleic anhydride monomer increases.
- The copolymer can be either in the anhydride or partial ester form. The copolymer can be partially esterified by treating the styrene/maleic anhydride copolymer with an alcohol such as ethylene glycol. The preferred degree of esterification of the copolymer is about 35 percent to about 50 percent.
- Thermoplastic synthetic resin adhesives comprise a variety of polymerized materials such as polyvinyl acetate, polyvinyl butyryl, polyvinyl alcohol, and other polyvinyl resins. Acrylic and methacrylic acid ester resins and various other synthetic resins such as polyisobutylene, polyamides, coumarone-indene products and silicones also exhibit adhesive properties desirable for the coating composition disclosed herein. The thermoplastic resins usually have permanent solubility and fusibility so that they creep under stress and soften when heated. The preferred thermoplastic resin herein is polyvinyl acetate (PVAc) which has demonstrated affinity for plaster and plaster-like compositions.
- The PVAc resin used in the composition disclosed herein can be in the form of beads such as VINAC beads manufactured by Air Products and Chemicals Inc. VINAC is a registered trademark of Air Products and Chemicals, Inc. PVAc resins are typically small, glass-like beads which have a number of uses such as laminating, label and hot melt adhesives, pigmented and grease-proof paper coatings, over print varnishes, industrial lacquers and coatings, printing inks, and textile sizes and finishes. PVAc resin is resistant to attack by weak acids, alkalies and salts, but is soluble in many organic solvents. PVAc resin generally has a softening point above about 120°C to about 165°C. Suitable PVAc resins generally have a molar viscosity of about 10 cps to about 75 cps in organic solvent. The number average molecular weight of the PVAc resin is about 90,000 to about 500,000. The resin contains no more than about 2% by weight volatile components.
- The ratio of styrene/maleic anhydride copolymer to PVAc resin in the coating composition is about 20:80 to about 80:20 parts by weight. The copolymer and resin are combined in an inert organic solvent. Organic solvents suitable for this application can be an aromatic solvent, a ketone, a chlorohydrocarbon and mixtures thereof. Solvents that will evaporate quickly at room temperature are preferred. Preferred solvents are toluene, methylethylketone and chloroethane, most preferably 1,1,1 trichloroethane. The organic solvent generally constitutes about 70 to about 95 parts by weight of the coating composition, most preferably about 87 percent by weight.
- The coating is then applied to the fastener by dipping, spraying, roller coating or another standard technique, such as by any of the techniques disclosed in Lat et al., U.S. Patent No. 4,964,774, the teachings of which are incorporated herein by reference. The liquid coating composition preferably has a low viscosity so that drops of coating do not form on the fastener when it is removed from the coating bath.
- The coated metal fastener is then removed from the coating bath and is dried at about ambient temperature. This is below the softening temperature of the thermoplastic resin in the coating composition. Preferably the temperature is in the range of about 60°F (15°C) to 100°F (38°C). The polymer in the coating may or may not be cross-linked. The degree of cross-linking in a particular instance is dependent upon the specific composition of the resin dispersed in the solvent and the cross-linking agent, and/or accelerators that may be present. After the coated fasteners are removed from the coating bath, bridges of coating may form between individual fasteners. When dry, these bridges are brittle and break easily without damaging the coating on the fasteners to which the bridges are attached.
- A coating composition was prepared in which methylethylketone (MEK) solvent (150 lbs), 1,1,1 trichloroethane solvent (130 lbs) and toluene solvent (12 lbs) were combined. A styrene/maleic anhydride copolymeric resin (35 lbs) (2625 A Resin obtained from Atochem, Inc.) and a polyvinyl acetate resin (25 lbs) (VINAC B-100 Resin obtained from Air Products Corp.) were uniformly dispersed in the organic solvent mixture using mechanical mixing. MEK (78 lbs) and 1,1,1 trichloroethane (40 lbs) were then added to the dispersed mixture along with a dye (1502) (Orazol dye from Ciba Giegy Corp.). The mixture was again mixed using mechanical agitation until uniform. A summary of the coating composition is in Table 1 below.
TABLE 1 Coating Composition lb wt % Methyl Ethyl Ketone 150 31.85 Toluene 130 27.6 1,1,1 Trichloroethane 12 2.55 Styrene/Maleic Anhydride [2625A Resin (Atochem Inc.)] 35 7.43 Polyvinyl Acetate [VINAC B-100 Resin (Air Products)] 25 5.31 Methyl Ethyl Ketone 78 16.56 1,1,1 Trichloroethane Solvent 40 8.49 Dye¹ 0.94 0.2 Total Weight
¹The dye can be, for example, Orazol red G dye or Orazol blue GN dye. Both dyes are available from Ciba Giegy Corp. - The coating composition contained 13 ± 0.25 percent solids, which was determined by using an evaporation method. The coating composition had an estimated viscosity of about 16-18 seconds using a #2 Zahn Cup.
- A
coated nail 10, as shown in FIGURES 1 and 2, constitutes a preferred embodiment of this invention. The head 11 of thecoated nail 10 is cupped, in a known manner, so as to provide a reservoir for a spackling compound applied over thecoated nail 10. - The
coated nail 10 has ametal body 12, which is made of carbon steel, preferably AISI C 1008 steel. Its metal surfaces are covered completely with aninner zinc layer 14, an intermediatechromate conversion layer 16, and an outer copolymer/thermoplastic resin coating 18. - The
inner zinc layer 14, as applied by a known electroplating process, has a thickness of at least 0.5 mm so as to comply with Federal Building Code FF-N-105B, which is referenced to ASTM Specification A641, Class 1,Type 2. Preferably, as applied over theinner zinc layer 14 by a known chromating process, thechromate conversion layer 16 is a golden yellow (yellow iridescent) chromate conversion layer. A dark olive drab or dark black chromate conversion layer may be alternatively applied over thezinc layer 14, if desired. - As applied over the zinc and chromate conversion layers by the method disclosed herein, preferably within about two weeks after such layers are applied, the other copolymer/
thermoplastic resin coating 18 has a thickness of about 0.2 mm to about 2 mm, preferably about 0.5 mm to 1.5 mm. - As shown in FIGURE 3, a plurality of coated
nails 20, each of which is similar to thecoated nail 10, are collated into a coil, to be coated generally as disclosed in Langas et al. U.S. Pat. No. 3,276,576. Eachnail 20 has acupped head 19 similar to the cupped head 11 of thecoated nail 10. - The nails are situated in a
rubber band 21 and formed into acoil 20. The metal surfaces of eachcoated nail 20 are covered completely with aninner zinc layer 14, as described above, and with an intermediatechromium conversion layer 16, as described above. - FIGURE 4 is a detailed view of a few coated nails in a coil which fits a magazine (not shown) of a fastener driving tool. The
wires 22 are affixed to the coatednails 20 bywelds 23. The zinc and chromate conversion layers are applied to eachcoated nail 20 before suchcoated nail 20 is situated between and welded to thewires 22. - A
coated staple 30, as shown in FIGURE 5, constitutes yet another embodiment of this invention. - The
coated staple 30 has a metal body, which is made of carbon steel, preferably AISI C 1008 steel. Its metal surfaces are covered completely with an inner zinc layer, as described above, an intermediate chromate conversion layer, as described above, and an outer, copolymer/thermoplastic resin coating, as described above. - The
coated staple 30 may be one of a series (not shown) of similar staples that are collated. The outer coating on each of such staples, including the coatedstaple 30, may be advantageously used to collate the staples by applying the coating to the staples after the staples have been placed in a series, in side-to-side relation to one another. - A
coated truss plate 40, as shown in FIGURE 6 constitutes yet another embodiment of this invention. - The
coated truss plate 40 is formed from aplanar member 42, from which a plurality ofpointed teeth 44 are struck. Thetruss plate 40 usually is made of carbon steel, such as AISI C 1008 steel. Preferably, thetruss plate 40 is covered in its entirety with an inner zinc layer, as described above, an intermediate chromium conversion layer, as described above, and an outer coating, as described above. - The
coated truss plate 40 may be alternatively made from a galvanized, i.e., zinc-coated, steel sheet, which sheet has been galvanized in a hot-dip or other process. When theteeth 44 are struck from theplanar member 42, the edges of theteeth 44 and the edges of the openings left in theplanar member 42 by theteeth 44 are exposed without any zinc coating on the exposed edges. To provide corrosion protection for the exposed edges, thetruss plate 40 may be then immersed in a phosphating bath so as to apply a phosphate coating on the exposed edges as well as on the other parts of the metal body. A zinc phosphate coating is preferred. An iron phosphate coating may be alternatively applied. Next, an intermediate chromate conversion layer, as described above, and an outer, coating, as described above, are applied to thetruss plate 40 in its entirety. The intermediate chromium conversion layer may be optionally omitted. - Nails made of AISI C 1008 steel are first cleaned in an alkaline earth metal bath, rinsed, pickled in an acidic bath, rinsed, galvanized, and rinsed again. The nails are galvanized so as to comply with ASTM Specification A641, Class 1,
Type 2. Next, a chromate conversion layer is applied to the nails. Thereafter, the thus treated nails are rinsed and over-coated. - Nails which have been galvanized and chromated are preferred to be coated with the coating composition. It is envisioned that the composition can be applied to fasteners that have not been galvanized or chromated but upon which the properties imparted by the coating would be desirable.
- The nails are collated into coils by means of the
wires 22. The coils are dipped into bath of coating composition as described in Example 1 above, to provide a dry coat thickness of about 0.5 mm to about 1.5 mm. The coating composition has a viscosity of less than about 100 cps. The coating is dried in a circulating air atmosphere at about ambient temperature, preferably about 60°F (15°C) to 100°F (38°C). - Due to the manner in which the coating is applied to the nails, bridges of coating between the nails may form even though the coating composition has a low viscosity. These bridges of coating harden as the coating is dried. These bridges could be problematic if they were too rigid and therefor not easily broken. For example, a coated coil of nails that is placed in a magazine of a driving tool would be unsatisfactory if the coating bridges caused the nails to bind in the magazine. Also, if the bridges, when broken, removed portions of the coating on the fastener, the fastener would be less effective for its intended purpose.
- Because the copolymer/thermoplastic resin coating is brittle when dried, the bridges that form during the coating process can be easily broken without damaging the coating on the fastener itself. The desired brittleness is provided by the styrene monomer in the copolymer.
- The coated fastener has a demonstrated affinity for plaster and plaster-like materials. The nails are thus particularly suited for use in drywall or plasterboard applications to fasten the plasterboard to wooden frames. After the plasterboard is fastened, a plaster spackling compound is applied over the seams and the exposed nail heads to make a uniform surface. If the spackling compound does not adhere to the nail head it may be visible through the overcoat, or a pocked or otherwise uneven surface could result. The appearance of the resulting surface would be unacceptable. Because the coating composition of the present invention has a demonstrated affinity for plaster-like materials, the spackling compound or other plaster based overcoat adheres to the fastener head and the desired uniform overcoat appearance is obtained.
- Various modifications may be made in the coating composition, coated metal fastener or method of coating without departing from the spirit and scope of the invention, as defined in the appended claims.
Claims (10)
- A metal fastener that adheres to plaster with a polymeric coating comprising a copolymer of an aromatic monomer with α,β unsaturation with carboxyl groups, said α,β unsaturated monomer selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and a thermoplastic resin over substantially its entire metal surface and contiguous therewith.
- The metal fastener of claim 1 wherein the aromatic monomer is styrene.
- The metal fastener of claim 1 or 2 wherein the monomer with α,β unsaturation is maleic anhydride.
- The metal fastener of one of claims 1 to 3 wherein the mole ratio of styrene monomer to maleic anhydride monomer in the copolymer is about 1 to about 1 to about 3 to about 1.
- The metal fastener of one of claims 1 to 4 wherein the ratio of the first resin to the second resin is about 20 to 80 to about 80 to 20 parts by weight.
- The metal fastener of one of claims 1 to 5 wherein the polymeric coating has a thickness in the range of about 0.2 to about 2 millimeters.
- The metal fastener of one of claims 1 to 6 wherein the metal fastener is a nail or a staple.
- The metal fastener of one of claims 1 to 6 wherein the metal fastener is a truss plate.
- A coating composition for a metal fastener of one of claims 1 to 8 comprising:
a copolymer of an aromatic monomer and a monomer with α,β unsaturation with carboxyl groups, said α,β unsaturated monomer selected from the group consisting of maleic acid, fumaric acid and maleic anhydride;
a thermoplastic synthetic resin adhesive;
and an inert organic solvent selected from the group consisting of aromatic solvents, ketones, chlorohydrocarbons, and mixtures thereof. - A process for coating a metal fastener of one of claims 1 to 8 comprising:
providing a reservoir of a coating material that comprises a mixture of a copolymer of a styrene monomer and maleic anhydride monomer wherein the ratio of styrene monomer to maleic anhydride monomer in the copolymer is about 1 to 1 to about 3 to 1 and a thermoplastic resin in an organic solvent selected from the group consisting of aromatic solvents, ketones, chlorohydrocarbons and mixtures thereof;
dipping a metal fastener into the reservoir containing the coating composition; and
drying the coated, metal fastener at about ambient temperature.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US07/659,236 US5149237A (en) | 1991-02-22 | 1991-02-22 | Coated metal fastener and coating composition therefor |
US659236 | 1991-02-22 |
Publications (2)
Publication Number | Publication Date |
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EP0505708A1 true EP0505708A1 (en) | 1992-09-30 |
EP0505708B1 EP0505708B1 (en) | 1995-04-12 |
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Application Number | Title | Priority Date | Filing Date |
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EP92102230A Expired - Lifetime EP0505708B1 (en) | 1991-02-22 | 1992-02-11 | Coated metal fastener and coating composition therefor |
Country Status (9)
Country | Link |
---|---|
US (2) | US5149237A (en) |
EP (1) | EP0505708B1 (en) |
JP (1) | JP2640706B2 (en) |
AU (1) | AU640854B2 (en) |
CA (1) | CA2060607A1 (en) |
DE (1) | DE69201990T2 (en) |
HK (1) | HK147395A (en) |
NZ (1) | NZ241674A (en) |
ZA (1) | ZA92836B (en) |
Cited By (3)
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WO2012033785A1 (en) * | 2010-09-07 | 2012-03-15 | Illinois Tool Works Inc. | Fastener coating formulation |
FR2968367A1 (en) * | 2010-12-07 | 2012-06-08 | Lafarge Gypsum Int | System for manufacturing dry wall such as partition wall and ceiling, comprises plate made of hydraulic binder, metal upright, and identical or different fixing units, where part of surface of body of the fixing unit is covered by adhesive |
CN102989649A (en) * | 2012-12-25 | 2013-03-27 | 沈阳市航达科技有限责任公司 | Organic top coating double-layer protecting method for galvanized steel fasteners |
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US5441373A (en) * | 1993-09-07 | 1995-08-15 | Illinois Tool Works Inc. | Coated fastener |
US5547325A (en) * | 1994-02-18 | 1996-08-20 | Utility Composites, Inc. | Nail packs made of composites having high compressive strength and flexural modules |
DE69505212T2 (en) * | 1994-08-19 | 1999-03-04 | Illinois Tool Works Inc., Glenview, Ill. | Fastening element with polymer-coated shaft |
US5489179A (en) * | 1994-08-19 | 1996-02-06 | Illinois Tool Works Inc. | Fastener and building assembly comprising workpiece, substrate, and fastener |
US5741104A (en) * | 1994-08-19 | 1998-04-21 | Illinois Tool Works Inc. | Steel fastener having grooved shank |
US5590495A (en) * | 1995-07-06 | 1997-01-07 | Bressler Group Inc. | Solar roofing system |
US6431430B1 (en) * | 1998-09-18 | 2002-08-13 | Stanley Fastening Systems, L.P. | Battery operated roofing nailer and nails therefor |
CA2292166A1 (en) | 1999-01-13 | 2000-07-13 | Kent B. Godsted | Chemically coated fasteners having improved penetration and withdrawal resistance |
US7011242B2 (en) * | 2001-12-07 | 2006-03-14 | Acme Staple Company, Inc. | Coated staple and fastening tool for the same |
US7563835B2 (en) * | 2001-12-28 | 2009-07-21 | Sun Chemical Corporation | Solventless universal colorants |
US6758018B2 (en) | 2002-02-01 | 2004-07-06 | Stanley Fastening Systems, L.P. | Power driven nails for sheathing having enlarged diameter heads for enhanced retention and method |
US7395925B2 (en) * | 2002-02-01 | 2008-07-08 | Stanley Fastening Systems, L.P. | Pallet nail with enlarged head |
US20040022601A1 (en) * | 2002-08-05 | 2004-02-05 | Meyer Gregory Scott | Jackscrew with coating |
US20040126201A1 (en) * | 2002-08-09 | 2004-07-01 | Brian Kobylinski | Color-coded staples |
US7581911B2 (en) * | 2002-09-18 | 2009-09-01 | Utility Composites International Limited | Plastic impact driven fasteners |
US6848607B2 (en) * | 2003-02-25 | 2005-02-01 | Acme Staple Company, Inc. | Fastening tool with modified driver travel path |
US20050147485A1 (en) * | 2003-06-30 | 2005-07-07 | Strunk Jeffrey L. | Self-filling fastener and method of making |
US7273337B2 (en) * | 2003-06-30 | 2007-09-25 | Illinois Tool Works Inc. | Partially coated fastener assembly and method for coating |
US20050013680A1 (en) * | 2003-07-18 | 2005-01-20 | Steve Karaga | Screws and methods of driving a screw into a workpiece |
US20050129932A1 (en) * | 2003-12-16 | 2005-06-16 | Briley Robert E. | Rivet and coating technique |
US20050232723A1 (en) * | 2004-04-16 | 2005-10-20 | Stanley Fastening Systems, L.P. | Fastener for use in adverse environmental conditions |
US20060016129A1 (en) * | 2004-07-23 | 2006-01-26 | Riese Frederick C | Downspout extension retaining device |
JP2006183305A (en) * | 2004-12-27 | 2006-07-13 | Aic:Kk | Fastener for building having nail hole cut-off performance |
US7618222B2 (en) * | 2006-03-01 | 2009-11-17 | Chi Hyun Kim | Collated fastener strips with opposing wire connectors |
US8333538B2 (en) * | 2006-05-12 | 2012-12-18 | Illinois Tool Works Inc. | Debris-free plastic collating strip for nails |
US8360703B2 (en) * | 2006-05-12 | 2013-01-29 | Illinois Tool Works Inc. | Debris-free plastic collating strip for nails |
US8047752B2 (en) * | 2007-06-25 | 2011-11-01 | Msi Technology L.L.C. | Fastener assembly and multi-layered structure |
DE102008052619B4 (en) * | 2008-10-21 | 2012-02-23 | Henkel Ag & Co. Kgaa | Cohesive bonding of wire-shaped individual elements by means of a two-layer system based on acrylate resins |
US8033005B1 (en) | 2008-12-02 | 2011-10-11 | Illinois Tool Works Inc. | Method for making debris-free nail collation |
US8251686B1 (en) | 2008-12-02 | 2012-08-28 | Illinois Tool Works Inc. | Apparatus for making debris-free nail collation |
US9057397B2 (en) * | 2010-09-22 | 2015-06-16 | Mcgard Llc | Chrome-plated fastener with organic coating |
CN111779749B (en) | 2016-06-17 | 2022-05-03 | 佐治亚-太平洋石膏有限责任公司 | Self-sealing fasteners, building panels, systems and methods |
US20210108663A1 (en) * | 2019-10-11 | 2021-04-15 | Thompson Handyman Services LLC | Multi-Fastener Supply Depletion Indicator |
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GB657703A (en) * | 1948-01-26 | 1951-09-26 | Karl Werner Torsten Moller | An improved method of increasing the holding power of metal elements in wood |
DE1519245B1 (en) * | 1964-07-02 | 1970-07-09 | Monsanto Co | Aqueous coating agents containing styrene homo- and copolymer dispersions |
CH671271A5 (en) * | 1986-07-07 | 1989-08-15 | Ebnoether Ag | Fixing element for hammering in partic. nail or clamp - has coating on shaft comprising vinyl] acetate copolymer, acrylate] or methacrylate]-unsatd. acid copolymer, opt. polyvinyl alcohol, etc. |
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US3146142A (en) * | 1960-06-07 | 1964-08-25 | Union Oil Co | Joint adhesives |
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US3853606A (en) * | 1971-01-19 | 1974-12-10 | Steel Corp | Coated metal fasteners |
US3814156A (en) * | 1971-09-27 | 1974-06-04 | Loctite Corp | Threaded articles with locking or sealing coatings |
US3983304A (en) * | 1973-09-19 | 1976-09-28 | Hi-Shear Corporation | Fastener with protective metal-organic base coating |
JPS521963U (en) * | 1975-06-24 | 1977-01-08 | ||
JPS5327617U (en) * | 1976-08-14 | 1978-03-09 | ||
DE2823301A1 (en) * | 1978-05-29 | 1979-12-13 | Hoechst Ag | Aqueous PLASTIC DISPERSION BASED ON VINYLESTER POLYMER |
JPS6036576A (en) * | 1983-08-10 | 1985-02-25 | Mitsui Toatsu Chem Inc | Composition for water-dispersed paint |
US4964774A (en) * | 1989-09-29 | 1990-10-23 | Illinois Tool Works Inc. | Coated metal fastener |
-
1991
- 1991-02-22 US US07/659,236 patent/US5149237A/en not_active Expired - Fee Related
-
1992
- 1992-02-04 CA CA002060607A patent/CA2060607A1/en not_active Abandoned
- 1992-02-05 ZA ZA92836A patent/ZA92836B/en unknown
- 1992-02-10 AU AU10829/92A patent/AU640854B2/en not_active Ceased
- 1992-02-11 DE DE69201990T patent/DE69201990T2/en not_active Expired - Fee Related
- 1992-02-11 EP EP92102230A patent/EP0505708B1/en not_active Expired - Lifetime
- 1992-02-20 NZ NZ241674A patent/NZ241674A/en unknown
- 1992-02-21 JP JP4070121A patent/JP2640706B2/en not_active Expired - Lifetime
- 1992-04-16 US US07/868,892 patent/US5476687A/en not_active Expired - Fee Related
-
1995
- 1995-09-14 HK HK147395A patent/HK147395A/en not_active IP Right Cessation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB657703A (en) * | 1948-01-26 | 1951-09-26 | Karl Werner Torsten Moller | An improved method of increasing the holding power of metal elements in wood |
DE1519245B1 (en) * | 1964-07-02 | 1970-07-09 | Monsanto Co | Aqueous coating agents containing styrene homo- and copolymer dispersions |
CH671271A5 (en) * | 1986-07-07 | 1989-08-15 | Ebnoether Ag | Fixing element for hammering in partic. nail or clamp - has coating on shaft comprising vinyl] acetate copolymer, acrylate] or methacrylate]-unsatd. acid copolymer, opt. polyvinyl alcohol, etc. |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012033785A1 (en) * | 2010-09-07 | 2012-03-15 | Illinois Tool Works Inc. | Fastener coating formulation |
US8882426B2 (en) | 2010-09-07 | 2014-11-11 | Illinois Tool Works Inc. | Fastener coating formulation |
FR2968367A1 (en) * | 2010-12-07 | 2012-06-08 | Lafarge Gypsum Int | System for manufacturing dry wall such as partition wall and ceiling, comprises plate made of hydraulic binder, metal upright, and identical or different fixing units, where part of surface of body of the fixing unit is covered by adhesive |
CN102989649A (en) * | 2012-12-25 | 2013-03-27 | 沈阳市航达科技有限责任公司 | Organic top coating double-layer protecting method for galvanized steel fasteners |
CN102989649B (en) * | 2012-12-25 | 2015-04-01 | 沈阳市航达科技有限责任公司 | Organic top coating double-layer protecting method for galvanized steel fasteners |
Also Published As
Publication number | Publication date |
---|---|
HK147395A (en) | 1995-09-22 |
AU1082992A (en) | 1992-08-20 |
DE69201990D1 (en) | 1995-05-18 |
JPH0593165A (en) | 1993-04-16 |
CA2060607A1 (en) | 1992-08-23 |
DE69201990T2 (en) | 1995-11-23 |
JP2640706B2 (en) | 1997-08-13 |
US5476687A (en) | 1995-12-19 |
ZA92836B (en) | 1993-01-27 |
AU640854B2 (en) | 1993-09-02 |
NZ241674A (en) | 1994-09-27 |
US5149237A (en) | 1992-09-22 |
EP0505708B1 (en) | 1995-04-12 |
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